Terminal connection and assembly



p 9, 1958 R. E. PHELON ETAL 2,851,546

TERMINAL CONNECTION AND ASSEMBLY Filed Oct. 13, 1955 nunvrlxYi l.

lNl/E N TOR S RUSSELL E. PHELON JOHN E MART/N ATTORNEYS United StatesPatent 9 TERMINAL CONNEQTEUN AND ASSEMBLY Russell E. Phelon, Longmeadow,and John F. Martin, Springfield, Mass., assignors to R. E. PhelonCompany, Ilia, EastLongmeadow, Mass., a corporation of Massac usettsApplication October 13, 1955,.Serial No. 540,178

9 Claims. (Cl. 200-30) The invention relates to a terminal device at, oradapted to be placed at, one wall of a box for providing an electrical'connection through the box wall from an exterior wire or wires to theelectrical mechanism withinthe box.

The general object of the invention is to provide a terminal device forthe above-stated purpose which is simple and inexpensive and which canbe readily assembled with or disassembled from the box Without the useof tools.

A more specific object of the invention is to provide a terminal devicesuch as referred to in combination with a magneto. breaker mechanism,the leaf spring of the breaker mechanism being directly connected withthe terminal device to constitute a terminal connection.

Further objects of the invention will be apparent from the drawing andfrom the following description and claims.

In the drawing wehave shown in detail a preferred embodiment. of theinvention, but it will be understood that various changes may be madefrom the construction shown, and that the drawing is not to be construedas defining or limiting the scope of the invention, the claims forming apart of this specification being relied upon for that purpose.

Of the drawing:

Fig. 1 is a front view of a magneto breaker mechanism having a terminalconnection and assembly embodying theinvention, the front cover beingomitted.

Fig. 2 is a fragmentary perspective View of the left portion of the boxshown in Fig. 1.

Fig. 3 is a horizontal sectional view taken along the line 3--i of Fig.1, and also showing the front cover.

Fig. 4 is, a fragmentary vertical sectional view taken along the line 44of Fig. 3.

Fig. 5 is a perspective view of the terminal device and of an attachedspring and breaker arm.

Fig. 6 is an enlarged perspective view of a sheet metal wire terminaladaptedto be: used in conjunction with a terminal connection embodyingthe invention.

Fig. 7 is an enlarged right side view of the insulating block of theterminal connection with wires attached thereto. by' means of the sheetmetal wire terminal shown in Fig. 8 is a sectional view taken along theline. 8-8 of. Fig- 7.

Referring to the drawing, 10 represents a box for enclosing anelectrical mechanism, and 'as illustrated this mechanism is a breakermechanism for a magneto. The box is preferably formed of metal and ithas a rear wall 12 and a peripheral wall 14 having outer and inner facesand: also having a front face 15. The wall 14 has an interior rabbet' 16which provides a second front face 17. A detachable front cover 18 isprovided which normally engages the wall 14 at one of the front, facesthereof, preferably at the face 17' in the rabbet 16. The cover is heldin place by screws, not shown, which enterholes 20, 20 in bosses on thebox wall 14. As shown, said wall has notches 22 and 24 for receivingoutwardly projecting tabs on the cover, one of said tabs being shownatr26 in Fig. 3:.

When the mechanism within the box is a magneto breaker; mechanism, therear wall 12 and the cover 18 are preferably apertured to receive ashaft 28 having. a breaker cam 30 carried thereby and located within,the box. A conventional wiper felt 31 may be. provided for the cam 38,thus being held in a notch in the wall 14 of the box. The details of thedisclosed breaker mechanism do not constitute any part of the present.invention, but the mechanism shown is similar to that shown in thecopending application of Russell E. Phelon, Serial No. 492,158, filedMarch 25, 1955, and entitled Magneto Mechanism.

Thev breaker mechanism, as shown, includes a stationary breaker point,32 carried by a bracket 34 secured by a screw 35 to the rear wall 12 ofthe box and thus grounded. Said mechanism also includes a movablebreaker point 36 carried by a rocker arm 38 having a bearing aperture 39for receiving a longitudinal pivot pin 40 carried by said box wall 12.The rocker arm, 38 has an extension 42 which is engaged by said cam 30on the shaft 28. A. spring 44 serves to bias the rocker arm 38 to movethe point 36 into engagement with the point 34, and the. spring alsoserves as a. conductor to provide an electrical connection to themovable breaker point 36.

A, terminal device, to which the present invention more. particularlyrelates, provides an electrical connection through one wall of the boxbetween, one or more exterior wires and the interior mechanism which maybe the described magneto breaker mechanism.

The peripheral wall 14 of the box has a notch 46 therein as shown inFig. 2 which notch is open at the front and is at least as wide at thefront as elsewhere. Preferably the notch is substantially rectangular. Ablock 48 of insulating material is provided, this block having outer andinner faces and a fiat front face 49 and having a central, portion 56which has the same size and shape as the notch 46 and which is adaptedto be entered in the notch from the front and to have a tight fittherein. The said portion 50 of the block substantially fills the notchwith the front face 49- of the block approximately flush with the frontface 15 of the wall 14. The block 50 has, wider outer and inner flangesor portions 52 and 5.4 which are spaced apart by a distance equal to thethickness of the box Wall 14. Said portions 52 and 54 provide grooves atthe sides of the central portion 50 and they engage the outer and innerfaces of the peripheral box wall 14 and, cooperate with said centralportion to firmly hold the block 48 against transverse movement withre.- spect to said wall 14. Said block 48 is insertable rearwardly insaid notch 46 and is removable forwardly therefrom. The block ispreferably provided at the front with a rabbet 56 which matches therabbet 16 in the box wall 14,, said, rabbet providing the block with asecond front wall which matches the second front wall 17 of the boxwall. When the block 48 is in place, the front cover 18 preferablyengages said second front wall of the block.

The block 48 has an aperture therein extending therethrough between theouter and inner faces thereof, and a conductor 58 extends through andfits said aperture, said conductor being exteriorly connectible to awire or wires and being interiorly connectible to the electricalmechanism within the box. The main front faceof the block isperpendicular to the axis of the aperture and of the conductor 58.

When themechanism within the box is a magneto breaker mechanism such asdescribed, the inner end of the conductor 58 is preferably directlyconnected with the outer end of the spring 44. As shown, the innerflange or portion 54 of the block 48 has a shallow transverse groovewhich receives and fits the outer end portion of is apertured to receivethe conductor 58. The conductor 58 is preferably a combined screw andrivet, and it has a noncircular enlargement 60 which prevents rotationand limits inward movement. The inner end portion of the conductor 58 isriveted over at 62 to hold and provide electrical connection with thespring 44. The transverse spring receiving groove in the block portion54 has at least one transverse wall that engages a corresponding edge ofthe spring to prevent any rotative movement of the spring about theconductor 58, and as shown said groove has two such Walls. The outer endportion of the conductor 58 is threaded and is engageable by a nut 64which constitute exterior means for the connection of wires.

Preferably, but not necessarily, the outer face of the block 48 hasinclined or beveled portions 66 and 68 which are at one side of theblock aperture and which extend to one edge of the block which edge isshown as being the rear edge. Said portions 66 and 68 are at oppositesides of a plane perpendicular to the main front face of the block andextending through the axis of the block aperture. As shown, the faceportion 66 has a larger angle of inclination than the face portion 68.The beveled face portions 66 and 68 adapt the terminal connection foruse with a sheet metal wire terminal 70 such as shown in Fig. 6. A rib69 is provided between the inclined portions 66 and 68.

The metal comprising the terminal 7 is bent to provide two loops orcurls 72 and 74 which are generally parallel and which are tapered inthe same direction. Said loops are curled rearwardly from the frontportion of the terminal. One of the loops, as for instance 72, may besubstantially larger than the other. Between the loops 72 and 74 themetal is substantially fiat and is apertured at 76 to receive a screwsuch as the threaded portion of the conductor 58.

When two insulated wires such as 78 and 80 are to be connected with theterminal connection, the insulation is removed at the ends of the wiresand said wires are thrust into the respective loops to the extentspermitted by the insulation as shown in Fig. 7. Then the terminal 70 isplaced on the block 48 with the conductor member 58 extending throughthe aperture 76, the inclined inner sides of the loops 72 and 74engaging and fitting the inclined face portions 66 and 68. The taper ofthe loops 72 and 74 and the inclination of the faces 66 and 68 are suchthat the front flat portion of the wire terminal is parallel with themain front portion of the block. A

washer 82 is placed on the conductor 58 between the nut 64 and theterminal 70. When the nut is tightened, the Washer 82. crushes the loops72 and 74 and provides good electrical connection between said wires 78and 80 and the conductor 58. The crushed loop 74 at the right is moreclearly shown in Fig. 8. The rib 69 engages the wire terminal to preventrotation of said terminal about the axes of the conductor 58.

When the electrical mechanism in the box is a magneto breaker mechanism,the parts shown in Fig. constitute a sub-assembly which can be initiallyassembled as a separate unit and which can be thereafter assembled as anentirety with the box and with the other parts of the breaker mechanism.With the box cover 18 not in place, the subassembly as shown in Fig. 5can be moved rearwardly relatively to the box, care being taken to seethat the central portion 50 of the block enters the notch 46 in the boxwall and to see that the pivot pin 40 enters the aperture 39 in therocker arm. The block 48 tightly fits the notch 46 in the wall and theblock is frictionally held. Furthermore, the cover 18 when in place andheld serves to prevent any forward movement of the block. inasmuch asthe spring 44 is firmly connected with the block 48, said spring servesto prevent any forward movement of the rocker arm 38. It will be obviousthat, with the cover 18 removed, the said subassembly can be readilyremoved forwardly.

The invention claimed is:

1. The combination of a box including a peripheral wall having outer andinner faces and a front face and provided with an open-front notch atleast as wide at the front thereof as elsewhere, a single unitary blockof insulating material having outer and inner faces and a fiat frontface and having a central portion which fits and substantially fillssaid notch and said block being insertable rearwardly in said notch andremovable forwardly therefrom and said block having outer and innerportions which are wider than the central portion and which engage theouter and inner faces of said peripheral wall adjacent the notch to holdsaid block against transverse movement with respect to said wall andwith its said central portion in said notch, the fiat front face of theblock being approximately fiush with the front face of the peripheralwall and said block having an aperture therein extending therethroughbetween the outer and inner faces thereof and said inner face of saidblock having a transverse shallow groove intersecting said aperture, amagneto circuit breaker mechanism within the box including a rocker armand including a leaf spring connected with said arm and adapted to serveas a conductor, the outer portion of said spring entering and fittingsaid groove in the inner face of the block and having an aperture inregister with said block aperture, an electrical conductor extendingthrough and fitting said block aperture and having exterior means forelectrical connection with exterior wires, said conductor also extendingthrough said spring aperture and engaging said spring to hold it infixed relation to said block, and a detachable front cover normallyengaging the front faces of said peripheral wall and of said block.

2. The combination of a box adapted for containing an electricalmechanism and including a peripheral wall having outer and inner facesand provided with an openfront notch at least as wide at the frontthereof as elsewhere, a single unitary block of insulating materialhaving outer and inner faces and having a central portion which fits andsubstantially fills said notch and which block is insertable rearwardlyin said notch and removable forwardly therefrom and has outer and innerportions which are wider than said central portion and engage the outerand inner faces of said wall adjacent the notch, said block having anaperture therein extending between said outer and inner faces thereofand said outer face of the block including a portion parallel with saidbox wall and also including two other portions which are transverselyspaced and located at opposite sides of a plane through the axis of saidaperture and which terminate at one edge of the block and are inwardlyinclined similarly to each other, and electrical conductor extendingthrough and fitting the aperture in said block and having means at itsinner end for electrical connection with a mechanism within said box,and a wire terminal connected with said electrical conductor at itsouter end and adapted for holding two electrical conductor wires and forproviding electrical connection therewith which said terminal includesparts that engage and fit said inclined portions of the front face ofthe block.

3. The combination as set forth in claim 2, wherein a rib is providedbetween said two inclined portions of the outer face of the block, andwherein said rib engages said terminal to prevent rotation of theterminal about the axis of the conductor in said aperture.

4. The combination as set forth in claim 2, wherein said wire terminalis formed of sheet metal and is apertured to receive said conductor andhas two transversely spaced rearwardly curled tapered loops which areadapted respectively for receiving and fitting two electrical conductorwires, said loops of the terminal engaging and fitting said inclinedportions of the front face of the block and being so tapered that thefront portion of the terminal is parallel with said parallel portion ofthe front face of the block of the terminal, and wherein a nut inthreaded engagement with said conductor engages a washer which engagessaid parallel front portion of the wire terminal.

5. The combination as set forth in claim 4, wherein wires are entered inand engaged with said loops of said terminal, and wherein said loops arepartly flattened where engaged by said washer so that each loop at theinner and outer side thereof is in firm engagement with thecorresponding wire.

6. The combination of a block of insulating material having an outerface and having an aperture therein which extends to said outer face,said outer face of the block including a portion perpendicular to theaxis of said aperture and also including two other portions whichterminate at one edge of the block and are inclined similarly to eachother and inwardly from the plane of said perpendicular portion of theblock face, the last said portions being transversely spaced and locatedat opposite sides of a plane perpendicular to said block face andextending through the axis of said aperture, an electrical conductorextending through and fitting the aperture in said block, and a wireterminal engaging said electrical conductor at its outer end and adaptedfor holding two electrical conductor wires and for providing electricalconnection therewith which said terminal includes parts that engage andfit said inclined portions of the front face of the block.

7. The combination as set forth in claim 6, wherein said wire terminalis formed of sheet metal and is apertured to receive said conductor andhas two transversely spaced rearwardly curled tapered loops which areadapted respectively for receiving and fitting two electrical conductorwires, said loops of the terminal engaging and fitting said inclinedportions of the front face of the block and being so tapered that thefront portion of the terminal is parallel with said parallel portion ofthe front face of the block of the terminal, and wherein a nut inthreaded engagement with said conductor engages a washer which engagessaid parallel front portion of the wire terminal.

8. The combination as set forth in claim 7, wherein wires are entered inand engaged with said loops of said terminal, and wherein said loops arepartly flattened where engaged by said washer so that each loop at theinner and outer side thereof is in firm engagement with thecorresponding wire.

9. The combination of a single unitary block of insulating materialhaving outer and inner faces and a fiat front face and formed withgrooves at its sides which provide a central portion adapted to fit andsubstantially fill an open-front notch in a box wall which block has anaperture therein extending therethrough between the outer and innerfaces there-of, said outer face of the block in cluding a portionperpendicular to the axis of said aperture and also including two otherportions which terminate at one edge of the block and are inclinedsimilarly to each other and inwardly from the plane of saidperpendicular portion of the block face which said inclined portions aretransversely spaced and located at opposite sides of a planeperpendicular to said front face and extending through the axis of saidaperture and said inner face of the block having a transverse shallowgroove intersecting said aperture, a rocker arm for a magneto circuitbreaker mechanism, a movable breaker point carried by said arm, a leafspring fixedly connected mechanically with said rocker arm andelectrically connected with said breaker point and adapted to serve as aconductor, the outer portion of said spring entering and fitting saidgroove in the inner face of the block and having an aperture in registerwith said block aperture, and an electrical conductor extending throughand fitting said block aperture and also extending through said springaperture and engaging said spring to hold it in fixed relation to saidblock, said conductor being threaded at its outer portion for engaging anut adapted to hold a wire terminal having two transversely spacedportions adapted respectively for engaging the transversely spacedinclined portions of the outer face of the block.

References Cited in the file of this patent UNITED STATES PATENTS1,685,563 Connolly Sept. 25, 1928 2,049,637 Baker Aug. 4, 1936 2,334,007Hutt Nov. 9, 1943 2,516,178 Bohannon July 25, 1950 2,531,110 Cisler Nov.21, 1950 2,682,570 Elliott June 29, 1954

